Journal of Manufacturing Processes最新文献_第10页

Experimental and Finite Element Analysis of adapted cutting fluid supply on tool temperature and wear progression in Inconel 718 turning

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-02-05 DOI: 10.1016/j.jmapro.2025.01.061

Hui Liu , Markus Meurer , Thomas Bergs

Cutting fluids are crucial when machining difficult-to-cut materials such as nickel-based alloys, as they facilitate heat removal from the tool-workpiece contact area and minimize heat generation through lubrication. In addition to conventional flood cooling, the application of high-pressure cutting fluids is proving to be an advanced method for increasing tool life and promoting efficient chip removal. Although the benefits of high-pressure cooling are well recognized, a comprehensive investigation of cutting fluid parameters, such as nozzle opening area and supply pressure, and their effects on machining performance have not yet been sufficiently investigated. This research presents an innovative prototype toolholder with adjustable nozzle designs and temperature measurement capability. This toolholder allows the nozzle opening cross-section to be modified without changing the cooling channels or nozzle angles. Integrated thermocouples within the toolholder provide real-time temperature monitoring during machining. Experimental findings reveal that nozzle geometry had no influence on the tool temperature for the investigated process parameters, provided that an effective chip break is achieved. At 80 bar, increased cutting fluid flow enhanced chip fragmentation for inserts with chip breakers and improved tool wear, leading to longer tool life. Additionally, greater cutting fluid coverage along the cutting edge significantly reduced tool wear, with data showing up to a 20% reduction in tool wear for optimal nozzle configurations. Simulation studies support the link between enhanced chip breaking and increased cutting fluid flow through the cutting zone. This study offers quantitative evidence that optimized nozzle design and fluid parameters can improve tool life and machining efficiency.

{"title":"Experimental and Finite Element Analysis of adapted cutting fluid supply on tool temperature and wear progression in Inconel 718 turning","authors":"Hui Liu , Markus Meurer , Thomas Bergs","doi":"10.1016/j.jmapro.2025.01.061","DOIUrl":"10.1016/j.jmapro.2025.01.061","url":null,"abstract":"<div><div>Cutting fluids are crucial when machining difficult-to-cut materials such as nickel-based alloys, as they facilitate heat removal from the tool-workpiece contact area and minimize heat generation through lubrication. In addition to conventional flood cooling, the application of high-pressure cutting fluids is proving to be an advanced method for increasing tool life and promoting efficient chip removal. Although the benefits of high-pressure cooling are well recognized, a comprehensive investigation of cutting fluid parameters, such as nozzle opening area and supply pressure, and their effects on machining performance have not yet been sufficiently investigated. This research presents an innovative prototype toolholder with adjustable nozzle designs and temperature measurement capability. This toolholder allows the nozzle opening cross-section to be modified without changing the cooling channels or nozzle angles. Integrated thermocouples within the toolholder provide real-time temperature monitoring during machining. Experimental findings reveal that nozzle geometry had no influence on the tool temperature for the investigated process parameters, provided that an effective chip break is achieved. At 80 bar, increased cutting fluid flow enhanced chip fragmentation for inserts with chip breakers and improved tool wear, leading to longer tool life. Additionally, greater cutting fluid coverage along the cutting edge significantly reduced tool wear, with data showing up to a 20% reduction in tool wear for optimal nozzle configurations. Simulation studies support the link between enhanced chip breaking and increased cutting fluid flow through the cutting zone. This study offers quantitative evidence that optimized nozzle design and fluid parameters can improve tool life and machining efficiency.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"137 ","pages":"Pages 166-180"},"PeriodicalIF":6.1,"publicationDate":"2025-02-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143322120","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Innovative multiscale simulation with experimental validation of ultrafast laser processing in silicon carbide (4H-SiC)

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-02-05 DOI: 10.1016/j.jmapro.2025.02.002

Jianguo Zhao , Xu Han , Fang Dong , Sheng Liu

This study explores the femtosecond laser ablation mechanism of silicon carbide(4H-SiC), a material renowned for its exceptional hardness and challenging machinability. Combining multiscale simulation techniques with experimental approaches, the ablation process induced by a single femtosecond laser pulse on 4H-SiC was successfully replicated. A multi-physics finite element method (FEM) model was developed, integrating the two-temperature model (TTM), the Fokker-Planck equation, and an ablation deformation framework. The FEM results demonstrated a deviation of <29 % from experimental data. Furthermore, an enhanced molecular dynamics (MD) model was established to address laser-semiconductor interactions and overcome challenges associated with semiconductor bandgaps. Simulation results showed strong agreement with experimental observations, validating the models and offering a robust theoretical foundation for semiconductor laser processing. These findings contribute to advancements in laser-based semiconductor manufacturing, with promising implications for high-end industrial applications.

{"title":"Innovative multiscale simulation with experimental validation of ultrafast laser processing in silicon carbide (4H-SiC)","authors":"Jianguo Zhao , Xu Han , Fang Dong , Sheng Liu","doi":"10.1016/j.jmapro.2025.02.002","DOIUrl":"10.1016/j.jmapro.2025.02.002","url":null,"abstract":"<div><div>This study explores the femtosecond laser ablation mechanism of silicon carbide(4H-SiC), a material renowned for its exceptional hardness and challenging machinability. Combining multiscale simulation techniques with experimental approaches, the ablation process induced by a single femtosecond laser pulse on 4H-SiC was successfully replicated. A multi-physics finite element method (FEM) model was developed, integrating the two-temperature model (TTM), the Fokker-Planck equation, and an ablation deformation framework. The FEM results demonstrated a deviation of <29 % from experimental data. Furthermore, an enhanced molecular dynamics (MD) model was established to address laser-semiconductor interactions and overcome challenges associated with semiconductor bandgaps. Simulation results showed strong agreement with experimental observations, validating the models and offering a robust theoretical foundation for semiconductor laser processing. These findings contribute to advancements in laser-based semiconductor manufacturing, with promising implications for high-end industrial applications.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"137 ","pages":"Pages 252-262"},"PeriodicalIF":6.1,"publicationDate":"2025-02-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143321633","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

A coupled thermal–mechanical–hydrodynamic model for cutting of Ni-based superalloys cooled by a vortex tube

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-02-05 DOI: 10.1016/j.jmapro.2025.01.070

Zhen Meng , Shaorong Lin , Zhongyue Su , Jing Ni , Baotao Wang , Zefei Zhu , Weiguang Liu

Introducing fluid media into cutting dynamics simulation models and analyzing the heat transfer mechanism during the machining process is a research focus in the field of aeroengine component machining. However, owing to the challenges in precisely defining the boundary conditions of fluid media, further research is needed to improve the accuracy of simulation models for cutting dynamics in fluid media. To improve the accuracy of cutting dynamics simulations, in this study, a step-by-step coupling approach is employed to develop a multifield dynamics model for nickel-based superalloy cutting that incorporates fluid dynamics. Building on a standard thermomechanical simulation model, a fluid-active Eulerian space is introduced into this model, facilitating deeper integration with the vortex tube cooling fluid model and the nickel-based superalloy cutting thermomechanical model. The experimental results show that the simulation model proposed in this paper achieves accuracies of 89.74 % and 91.24 % in predicting the cutting force and cutting temperature, respectively, when vortex tube cooling is applied to nickel-based superalloys. Additionally, the prediction of the chip morphology is relatively accurate. Based on the experimental and simulation results, the cooling effect of the vortex tube is pronounced. To delve deeper into the heat transfer mechanisms, a flow field simulation model is developed from the multifield coupled model to examine the influence of cold airflow on convective heat transfer during cutting with vortex cooling. The fluid velocity and turbulence on the tool rake face are high, with a pronounced temperature difference and a correspondingly high heat transfer coefficient. In the chip and unmachined surface areas, the interplay between wall jets and the cold airflow recirculation region effectively enhances convective heat transfer. Consequently, the average heat transfer coefficient on the tool rake face when vortex tube cooling is used is notably greater than that during dry cutting. Hence, the direct incorporation of the cooling gas into the cutting simulation model enhances the accuracy and realism of the predictions, providing valuable insights into the intricate interactions between the various physical fields that exist during the cutting process.

{"title":"A coupled thermal–mechanical–hydrodynamic model for cutting of Ni-based superalloys cooled by a vortex tube","authors":"Zhen Meng , Shaorong Lin , Zhongyue Su , Jing Ni , Baotao Wang , Zefei Zhu , Weiguang Liu","doi":"10.1016/j.jmapro.2025.01.070","DOIUrl":"10.1016/j.jmapro.2025.01.070","url":null,"abstract":"<div><div>Introducing fluid media into cutting dynamics simulation models and analyzing the heat transfer mechanism during the machining process is a research focus in the field of aeroengine component machining. However, owing to the challenges in precisely defining the boundary conditions of fluid media, further research is needed to improve the accuracy of simulation models for cutting dynamics in fluid media. To improve the accuracy of cutting dynamics simulations, in this study, a step-by-step coupling approach is employed to develop a multifield dynamics model for nickel-based superalloy cutting that incorporates fluid dynamics. Building on a standard thermomechanical simulation model, a fluid-active Eulerian space is introduced into this model, facilitating deeper integration with the vortex tube cooling fluid model and the nickel-based superalloy cutting thermomechanical model. The experimental results show that the simulation model proposed in this paper achieves accuracies of 89.74 % and 91.24 % in predicting the cutting force and cutting temperature, respectively, when vortex tube cooling is applied to nickel-based superalloys. Additionally, the prediction of the chip morphology is relatively accurate. Based on the experimental and simulation results, the cooling effect of the vortex tube is pronounced. To delve deeper into the heat transfer mechanisms, a flow field simulation model is developed from the multifield coupled model to examine the influence of cold airflow on convective heat transfer during cutting with vortex cooling. The fluid velocity and turbulence on the tool rake face are high, with a pronounced temperature difference and a correspondingly high heat transfer coefficient. In the chip and unmachined surface areas, the interplay between wall jets and the cold airflow recirculation region effectively enhances convective heat transfer. Consequently, the average heat transfer coefficient on the tool rake face when vortex tube cooling is used is notably greater than that during dry cutting. Hence, the direct incorporation of the cooling gas into the cutting simulation model enhances the accuracy and realism of the predictions, providing valuable insights into the intricate interactions between the various physical fields that exist during the cutting process.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"137 ","pages":"Pages 181-195"},"PeriodicalIF":6.1,"publicationDate":"2025-02-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143322119","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

3D curved surface milling modeling for the topography simulation and surface roughness prediction

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-02-05 DOI: 10.1016/j.jmapro.2025.02.003

Cong Chen , Chongjun Wu , Tangyong Zhang , Steven Y. Liang

Machining complex contoured parts is a critical task in high performance manufacturing, of which the curved surface are the predominant features in high-end parts. This paper aims to the three-dimensional surface topography simulation and roughness prediction in the context of curved surface milling. According to the geometry of ball-end milling cutter and the tool-workpiece contact situation, this study proposes the concept of effective cutting edges. By combining cutting geometry, kinematics and elastic-plastic deformation mechanism, a comprehensive prediction model is constructed by considering machine verticality, milling type, spindle dynamic balance and other factors. This model simulates three-dimensional surface topography and predicts roughness based on the surface residual height. To validate the prediction model accuracy, a series of orthogonal experiments were designed in this paper, and the results were used to analyze the influence of machining parameters on cutting force and machined surface roughness. The results indicate that the average relative error in roughness prediction under curved surface milling conditions is 4.59 %, with a minimum relative error of 0.49 %. Additionally, the model simulation aligns closely with the surface residual characteristics after actual milling. This study also identified step distance and curvature as primary factors influencing surface roughness and cutting force in curved surface milling. Finally, the process parameters, such as the feed speed, step distance and axial cutting depth, are quantitatively correlated with surface roughness and cutting forces.

{"title":"3D curved surface milling modeling for the topography simulation and surface roughness prediction","authors":"Cong Chen , Chongjun Wu , Tangyong Zhang , Steven Y. Liang","doi":"10.1016/j.jmapro.2025.02.003","DOIUrl":"10.1016/j.jmapro.2025.02.003","url":null,"abstract":"<div><div>Machining complex contoured parts is a critical task in high performance manufacturing, of which the curved surface are the predominant features in high-end parts. This paper aims to the three-dimensional surface topography simulation and roughness prediction in the context of curved surface milling. According to the geometry of ball-end milling cutter and the tool-workpiece contact situation, this study proposes the concept of effective cutting edges. By combining cutting geometry, kinematics and elastic-plastic deformation mechanism, a comprehensive prediction model is constructed by considering machine verticality, milling type, spindle dynamic balance and other factors. This model simulates three-dimensional surface topography and predicts roughness based on the surface residual height. To validate the prediction model accuracy, a series of orthogonal experiments were designed in this paper, and the results were used to analyze the influence of machining parameters on cutting force and machined surface roughness. The results indicate that the average relative error in roughness prediction under curved surface milling conditions is 4.59 %, with a minimum relative error of 0.49 %. Additionally, the model simulation aligns closely with the surface residual characteristics after actual milling. This study also identified step distance and curvature as primary factors influencing surface roughness and cutting force in curved surface milling. Finally, the process parameters, such as the feed speed, step distance and axial cutting depth, are quantitatively correlated with surface roughness and cutting forces.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"137 ","pages":"Pages 150-165"},"PeriodicalIF":6.1,"publicationDate":"2025-02-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143322117","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Hybrid optimization strategies for improved machinability of nitronic-50 with MT-PVD inserts

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-02-05 DOI: 10.1016/j.jmapro.2025.01.092

Ayan Banerjee, Kalipada Maity

Dry-turning operations using MT-PVD inserts were performed on Nitronic-50 under combinations of three distinct levels of cutting velocities, feeds and cutting depths, adopting a face-centered central composite design. Study includes comprehensive investigation of responses such as tangential cutting force, tool-tip temperature, flank wear, material removal rate and surface roughness. Experimental results are correlated with simulated and predicted findings. Wear characteristics indicated that attrition, abrasion, craters, coating delamination, adhesion, and edge-chipping were the predominant forms observed. Simulated wear was evaluated using Usuis's tool wear criterion. ANOVA analyses showed responses to be mainly affected by depth of cut and cutting velocity. RSM-based regression models and corresponding surface plots led to efficient understanding of response behaviour under parametric variations. Additionally, process parameters have been optimized using MCDM, hybrid MCDM and MCDM-integrated metaheuristic techniques. Confirmation test results post-optimization speak in favour of 50 m/min as cutting velocity, 0.0884 mm/rev as feed and 0.1 mm as cutting depth obtained with TLBO, which offered significant reductions in tangential cutting force, tool-tip temperature, flank wear and surface roughness. MRR was obtained higher under optimal setting of 100 m/min as cutting velocity, 0.08 mm/rev as feed and 0.5 mm as cutting depth under MOORA method.

{"title":"Hybrid optimization strategies for improved machinability of nitronic-50 with MT-PVD inserts","authors":"Ayan Banerjee, Kalipada Maity","doi":"10.1016/j.jmapro.2025.01.092","DOIUrl":"10.1016/j.jmapro.2025.01.092","url":null,"abstract":"<div><div>Dry-turning operations using MT-PVD inserts were performed on Nitronic-50 under combinations of three distinct levels of cutting velocities, feeds and cutting depths, adopting a face-centered central composite design. Study includes comprehensive investigation of responses such as tangential cutting force, tool-tip temperature, flank wear, material removal rate and surface roughness. Experimental results are correlated with simulated and predicted findings. Wear characteristics indicated that attrition, abrasion, craters, coating delamination, adhesion, and edge-chipping were the predominant forms observed. Simulated wear was evaluated using Usuis's tool wear criterion. ANOVA analyses showed responses to be mainly affected by depth of cut and cutting velocity. RSM-based regression models and corresponding surface plots led to efficient understanding of response behaviour under parametric variations. Additionally, process parameters have been optimized using MCDM, hybrid MCDM and MCDM-integrated metaheuristic techniques. Confirmation test results post-optimization speak in favour of 50 m/min as cutting velocity, 0.0884 mm/rev as feed and 0.1 mm as cutting depth obtained with TLBO, which offered significant reductions in tangential cutting force, tool-tip temperature, flank wear and surface roughness. MRR was obtained higher under optimal setting of 100 m/min as cutting velocity, 0.08 mm/rev as feed and 0.5 mm as cutting depth under MOORA method.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"137 ","pages":"Pages 221-251"},"PeriodicalIF":6.1,"publicationDate":"2025-02-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143322137","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Transformation of material removal behavior and its mechanism modeling with the wear evolution of pyramidal structured abrasive belts

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-02-04 DOI: 10.1016/j.jmapro.2025.01.094

Yingjie Liu , Wenxi Wang , Shaoze Yan , Lei Wan , Lai Zou

The study focused on investigating the wear and material removal behavior of pyramidal structured abrasive belts used for grinding aero-engine blades. It aims to develop a mechanism model that could effectively couple the effects of time-varying wear and explain the material removal evolution. Experimental results demonstrated a unique transition phenomenon from macroscopic to microscopic cutting behavior during the initial wear stage, followed by a synchronized exponential decline phase in both material removal and abrasive belt's mass loss. To address this trend, the paper has proposed a material removal model by combining Hertz contact model, Archard wear model, and Preston equation. The model's validity was confirmed through comparison with existing literature, and a verification experiment with an average error of 5.94 %.

引用次数: 0

Laser spheroidization combined with coaxial powder feeding: A novel strategy for preparing spherical powders for additive manufacturing

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-02-04 DOI: 10.1016/j.jmapro.2025.01.062

Wanneng Zhang , Lu Wang , Ying Liu , Renquan Wang , Dongting Li

Spherical powders are essential for ensuring the quality of parts produced via additive manufacturing (AM). However, powders prepared using traditional methods often suffer from wide particle size distributions, high impurity content, and poor sphericity, which hinder the advancement of AM. This study presents a novel laser spheroidization technique combined with coaxial powder feeding to produce high-quality spherical powders for AM. The spheroidization process was analyzed through multi-source observations and theoretical calculations. The effects of laser spot diameter, powder feed rate, and carrier gas flow on the powder spheroidization ratio were investigated. Using response surface methodology (RSM), the optimal processing parameters were determined as 8.35 mm, 2.0 g/min, and 2.0 L/min, respectively. Under these conditions, the spheroidization ratio of iron powder exceeded 96 %, with a sphericity close to 100 %. The spheroidized powder also exhibited excellent properties, including a narrow particle size distribution, absence of internal porosity defects, and high powder purity. The flowability of the iron powder improved significantly, from 31.4 s/50 g to 12.6 s/50 g. Moreover, this method is not limited to specific materials and is also effective for spheroidizing other powders, including dendritic nickel, reactive titanium alloy, and refractory tungsten carbide. This work offers an approach for fabricating high-quality spherical powders, providing innovative solutions to the challenges associated with traditional manufacturing methods.

{"title":"Laser spheroidization combined with coaxial powder feeding: A novel strategy for preparing spherical powders for additive manufacturing","authors":"Wanneng Zhang , Lu Wang , Ying Liu , Renquan Wang , Dongting Li","doi":"10.1016/j.jmapro.2025.01.062","DOIUrl":"10.1016/j.jmapro.2025.01.062","url":null,"abstract":"<div><div>Spherical powders are essential for ensuring the quality of parts produced via additive manufacturing (AM). However, powders prepared using traditional methods often suffer from wide particle size distributions, high impurity content, and poor sphericity, which hinder the advancement of AM. This study presents a novel laser spheroidization technique combined with coaxial powder feeding to produce high-quality spherical powders for AM. The spheroidization process was analyzed through multi-source observations and theoretical calculations. The effects of laser spot diameter, powder feed rate, and carrier gas flow on the powder spheroidization ratio were investigated. Using response surface methodology (RSM), the optimal processing parameters were determined as 8.35 mm, 2.0 g/min, and 2.0 L/min, respectively. Under these conditions, the spheroidization ratio of iron powder exceeded 96 %, with a sphericity close to 100 %. The spheroidized powder also exhibited excellent properties, including a narrow particle size distribution, absence of internal porosity defects, and high powder purity. The flowability of the iron powder improved significantly, from 31.4 s/50 g to 12.6 s/50 g. Moreover, this method is not limited to specific materials and is also effective for spheroidizing other powders, including dendritic nickel, reactive titanium alloy, and refractory tungsten carbide. This work offers an approach for fabricating high-quality spherical powders, providing innovative solutions to the challenges associated with traditional manufacturing methods.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"137 ","pages":"Pages 82-99"},"PeriodicalIF":6.1,"publicationDate":"2025-02-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143321263","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Mechanistic understanding of microstructure evolution in extrusion-based additive manufacturing of stainless steel using modeling, simulation, and experimental analysis

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-02-03 DOI: 10.1016/j.jmapro.2025.01.084

Dayue Jiang , Yue Zhou , Mark D. Poliks , Peter Borgesen , Fuda Ning

Extrusion-based additive manufacturing (AM) has been widely adopted as a cost-effective approach to building metal materials for engineering applications. The final microstructure and properties are strongly dependent on the post-processing, e.g., debinding and sintering, of the as-printed part. In this study, the structure evolution at a microscopic length scale during this extrusion-based AM process was understood by discrete element modeling, simulation, and experimental validation. In the simulation three groups of stainless-steel particles were placed with different distribution patterns by imposing different packing strategies. By considering both surface and grain boundary diffusion mechanisms during modeling and simulation, the microstructural evolution, including pore size reduction and grain growth were revealed. Effects of particle distribution patterns on the grain and pore morphology during sintering have also been uncovered. The simulation results were experimentally validated by characterizing stainless steel specimens at different sintering stages through X-ray computed tomography and microscopies, indicating their good alignment with the realistic microstructure evolution. The research findings from this study provide valuable insights into unique sintering behaviors affected by AM and guide the process optimization for metal alloys fabricated through the extrusion-based sintering-assisted AM process.

{"title":"Mechanistic understanding of microstructure evolution in extrusion-based additive manufacturing of stainless steel using modeling, simulation, and experimental analysis","authors":"Dayue Jiang , Yue Zhou , Mark D. Poliks , Peter Borgesen , Fuda Ning","doi":"10.1016/j.jmapro.2025.01.084","DOIUrl":"10.1016/j.jmapro.2025.01.084","url":null,"abstract":"<div><div>Extrusion-based additive manufacturing (AM) has been widely adopted as a cost-effective approach to building metal materials for engineering applications. The final microstructure and properties are strongly dependent on the post-processing, e.g., debinding and sintering, of the as-printed part. In this study, the structure evolution at a microscopic length scale during this extrusion-based AM process was understood by discrete element modeling, simulation, and experimental validation. In the simulation three groups of stainless-steel particles were placed with different distribution patterns by imposing different packing strategies. By considering both surface and grain boundary diffusion mechanisms during modeling and simulation, the microstructural evolution, including pore size reduction and grain growth were revealed. Effects of particle distribution patterns on the grain and pore morphology during sintering have also been uncovered. The simulation results were experimentally validated by characterizing stainless steel specimens at different sintering stages through X-ray computed tomography and microscopies, indicating their good alignment with the realistic microstructure evolution. The research findings from this study provide valuable insights into unique sintering behaviors affected by AM and guide the process optimization for metal alloys fabricated through the extrusion-based sintering-assisted AM process.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"137 ","pages":"Pages 68-81"},"PeriodicalIF":6.1,"publicationDate":"2025-02-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143321780","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Investigating the influence of target distance in laser offline measurement based on self-mixing interference and its potential for monitoring additive manufacturing processes

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-02-01 DOI: 10.1016/j.jmapro.2025.01.058

Feng Lin , Yuanfu Tan , Mubasher Ali , Zhou Su , Wei-Hsin Liao , Hay Wong

Laser-based Directed Energy Deposition (LDED) is influenced by various factors such as process parameters during the layer-by-layer deposition process, which leads to severe defects and the unstable mechanical properties of the fabricated parts. Monitoring and measuring the dimensions and defects of the parts during the manufacturing process can facilitate real-time adjustments of process parameters to improve the yield of the manufacturing process. However, the existing LDED equipment imposes challenging environmental conditions for millimeter-range measurement methods, and the processing area sizes are different which require different measurement distances. Existing measurement methods often encounter issues such as reduced measurement accuracy or complex data processing when implementing centimetre-range measurements. Therefore, this paper proposes an offline measurement method based on laser self-mixing interference and investigates the influence of distance targets on the feedback signal received. Our in-house developed measurement device utilized a 200 mW near-infrared laser diode to measure the dimensions of a series of centimetre-sized single-wall samples processed with Polylactic Acid (PLA) polymer, 1064 Aluminium alloy, and 316L stainless steel. By processing the feedback signals, the dimensions of the defects within the target can be determined. Experimental results demonstrate that the measurement accuracy can reach up to 99.620 % for a target positioned within 300 mm. The results showcase the potential of our proposed measurement method in the field of additive manufacturing process monitoring.

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引用次数: 0

Ultra-precision turning path planning approaches based on distribution characteristics of improved constrained NUBS interpolated surface parameters

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-02-01 DOI: 10.1016/j.jmapro.2025.01.043

Shuai He , Leilei Zhang , Tielin Shi

To improve the ultra-precision turning performance and efficiency of NUBS surfaces, this study proposes two general tool path generation methods based on improved constrained NUBS global surface parameters. The NUBS global surface interpolation method in the radial Cartesian coordinate system(RCCS) is improved by leveraging the strong linear correlation between parameters and arc length. This enhancement ensures a linear relationship between radial global parameters and radial curve arc length, strengthens the circumferential correlation, and improves surface continuity and interpolation accuracy. Then, using the NUBS surface parameters, the simultaneous control spiral path generation method (SC-SPGM) with a quite low calculation cost is proposed, in which the linearly varying parameters

u, v

in the path ensure the equal spatial pitch and equal-arc-length discrete intervals. Furthermore, to enhance the accuracy of equal-arc-length discretization of SC-SPGM, the non-simultaneous control spiral path generation method (NSC-SPGM) is proposed, which uses the linear correlation between the NUBS interpolation curve parameters and the arc length. The proposed methods are verified by several simulation analyses and processing experiments, showing good performance in controlling tool residual height (TRH) and equal-arc-length discretization.

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引用次数: 0